Caravan AWD V6-201 3.3L (1991)
Caution:
Do not disturb the pump end of the low pressure hose. After removing the connector block, the low pressure hose is only retained by the internal O-ring
seal.
12.
Remove the high pressure hose from the vehicle.
13.
Clean the pump contact face for the high pressure hose. Use Mopar Brake Parts Cleaner (PN 4549623) or equivalent.
14.
Lubricate the supplied O-rings with brake fluid and install the large O-ring on the connector block face and the small O-ring on the cleaned
banjo bolt.
15.
Install the new high pressure hose (parts package number C3940470), fastening the connector block end to the pump face with the banjo bolt.
Torque to 10 ft.lbs. (14 N-m).
16.
Route the high pressure hose along the low pressure hose to the reservoir.
Important:
The high pressure hose must be routed along the left (driver's) side of the low pressure hose by the battery tray and over the low pressure hose to the
hydraulic assembly. This is necessary for proper positioning of the hose clip to the battery tray in step 18.
17.
Remove the cap from the fitting on the high pressure hose and install the end of the high pressure hose to the reservoir. Torque to 145 in.lbs.
(16 N-m).
18.
Attach the supplied high pressure hose clip to the high and low pressure hoses and attach the clip to the battery tray. Position the low pressure
hose in the smaller loop of the clip and the high pressure hose in the larger loop for proper orientation of the clip.
19.
Install the 4 supplied tie wraps around the hose assembly and wiring harness (Figure 6).
20.
Reinstall the air cleaner assembly and fresh air intake duct.
21.
Reconnect the battery ground.
22.
Turn the ignition switch to the ON position to start the brake booster pump. Apply the brake pedal several times to distribute the fluid.
23.
Check the master cylinder reservoir fluid level by performing the following procedure:
^
Turn the ignition OFF and pump the brake pedal 40 to 50 times, until the pedal is hard. The fluid level should be at the top of the inlet
screen. Add brake fluid as necessary using new Mopar brake fluid or an equivalent with SAE 1703 and DOT 3 ratings.
24.
Start the vehicle and evaluate the brakes for proper function.
No other service action is necessary for these vehicles.
III Pump and High Pressure Hose Replacement
III. Replace Pump and High Pressure Hose
If pump replacement is required (see pump inspection, Section II step # 4 of this Service Procedure), proceed as follows.
